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Arc-directed energy deposition for hot forging mold cavity with conformal cooling channels

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Abstract

The service life of hot forging molds is seriously reduced under high-temperature load for a long time. Arc-directed energy deposition (ADED) high-precision hot forging mold cavity with conformal cooling channels (HFMCCC) in the mold cavity, reducing the working temperature of the mold and forming an isothermal field is an effective method to improve the life of hot forging mold. Based on the space-curved surface structure of HFMCCC, the manufacturing partition strategy of which is studied. In order to avoid interference of the arc torch in the process of manufacturing the joint of the left and right sub-areas and corner of the CCC, combined with the depth of the cavity, the U-shape, and the quadrilateral structure inside the hot forging mold, it is divided into four regions: the transition region and the upper, middle, and lower regions. The path planning strategy of offset filling is applied to the transition region; scanning composite offset filling is applied to regions containing U-shaped and quadrilateral features, and an arc torch with contour-varying posture is applied to CCC regions. The visual interference and posture optimization of the printing path are carried out by using simulation software, and the printing path robot instructions in four areas are obtained. ADED the hot forging model cavity of the double-layer space curved conformal channel. The forming accuracy of CCC is 0.568 mm, and the average deviation of HFMCCC is 0.713 mm. Under the same working conditions, the temperature gradient field of the conformal channel mold is 5 ℃/cm, while the temperature gradient field of the traditional linear channel is 12 ℃/cm. The temperature gradient field difference of the conformal channel mold is 7 ℃/cm smaller than that of the traditional straight channel mold.

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Funding

This work was supported by the National Key R&D Program of China, No.2017YFB1103200.

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Authors and Affiliations

  1. State Key Laboratory of Materials Processing and Die & Mould Technology, Huazhong University of Science and Technology, Luoyu Road 1037, Wuhan, China

    Haitao Lin, Shengfu Yu, Runzhen Yu & Bo Zheng

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  1. Haitao Lin
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  2. Shengfu Yu
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  3. Runzhen Yu
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  4. Bo Zheng
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Contributions

All authors have contributed to the development of the research and to the elaboration of this paper.

Haitao Lin: investigation, formal analysis, data curation, writing and editing the original draft.

Shengfu Yu: writing-review and editing, supervision, and funding acquisition.

Runzhen Yu and Bo Zheng: resources and data curation.

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Correspondence to Shengfu Yu.

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Lin, H., Yu, S., Yu, R. et al. Arc-directed energy deposition for hot forging mold cavity with conformal cooling channels. Int J Adv Manuf Technol 125, 4453–4466 (2023). https://doi.org/10.1007/s00170-023-10844-0

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